Electrical junction box cover and related assemblies and methods for completing electrical installations

ABSTRACT

This invention relates to electrical junction box covers for temporary use during application of drywall and other finish work. Electrical junction boxes include any type of electrical outlet or switch box, including communication boxes for cable, Ethernet, phone, or any other related system. The covers of the invention prevent debris from entering the electrical junction boxes during the application of drywall and finish work. The covers protect electrical and data cabling and provide substantial efficiencies in construction of residential and commercial structures.

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/212,963 filed Sep. 1, 2016. The above referenced provisionalpatent application is incorporated herein by reference as if restated infull. All references cited herein, including, but not limited to patentsand patent applications, are incorporated by reference in theirentirety.

BACKGROUND

Construction of residential and commercial structures involves multiplephases and tradespeople. The steps are generally completed in a specificorder, and each step may depend on completion of the preceding step.Also, because the construction of such structures inherently involvestradespeople with different expertise, it is common for separateconstruction steps to depend on completion of an earlier step and to beperformed by completely different personnel.

The current construction process generally includes:

-   1) Framers erect the walls, floors and ceilings of the structure.    The walls may be constructed of wood or metal studs, and the floor    and ceiling joists of wood or metal beams;-   2) After rough framing of walls is complete and before erecting the    wall panels, a tradesperson such as an electrician installs    dedicated electrical junction boxes for electrical and data    communication wiring by attaching the boxes to the wall studs or    ceiling joists;-   3) The electrician routes wiring from a main panel to each box,    depending on the function intended for the box and the access that    will be provided to the occupant. The installation is a rough    process where the wiring and junctions are not active (e.g., hot).    In current practices, wires and cabling with bare terminal ends are    capped off, rolled up and pushed back into the box. Thus, terminal    end of the cables are typically not connected to their intended    fixture, such as a light switch, electrical outlet or data port    until completion of a later finishing step as described below;-   4) Drywall installers install drywall over the walls and ceilings by    attach the wall panels to the studs and joists. To allow access to    the electrical junction boxes, the drywall installers rough cut a    hole to accommodate the electrical junction box and remove the    resulting cut-out panels from the drywall using a router or other    rough cut tool. The shape of the cut out opening is meant to roughly    match the shape of the electrical junction box, so that the    resulting drywall surface will closely surround the junction boxes    that are already in place. During drywall installation, it is common    that cutting out holes for one or more of the junction boxes is    inadvertently missed and the box becomes permanently covered. This    typically occurs if the box did not protrude enough from the stud    when the box was attached to the stud. Also, some cut outs in the    drywall may not be properly shaped and will require repairs to the    drywall surrounding the protruding junction box. Such repairs    are-typically performed with dry wall tape and joint compound, which    is a spreadable sealant commonly referred to as “mud,” to clean up    the final appearance-of the drywall surrounding the junction box.    Also, because the drywall installers do not have ultimate    responsibility for completing the electrical and data connections,    it is common for drywall installers to cut or damage wires and    cabling during installation of the drywall panels;-   5) Once drywall is hung and boxes have been cut out, drywall    installers finish seams beneath the drywall sheets using tape and    sealant and typically finish the border around the electrical    junction boxes with joint compound to create a sealed border around    the periphery of the junction boxes. The drywall installers may also    texture the drywall and repair any imperfections in the final wall    panels. During this process, extra joint compound and debris is    commonly pushed into the previously installed electrical junction    boxes and this debris can cover the terminal ends of the wiring and    cabling and can damage the wires/cables thereby making future    connection of sockets, switches, or data ports more difficult;-   6) Once the drywall process is completed the electrician returns to    the job to complete the installation of the outlet, switch or    communication fixture intended for the junction box. At this point,    the electrician must clean and repair each junction box by hand to    remove excess joint compound and debris prior to installing the hot    outlets, switches, and communication wiring.

Another challenge confronting the electrician is the need to pull theelectrical junction box away from the point of attachment of theelectrical junction box to the wall beams to align the outer edge of thejunction box with the planar surface of the drywall. Typically this isdone by manually grabbing the metal outlet tabs that are provided onoutlets and plugs. However, these structures are not designed for thispurpose and are often flimsy due to damage to the drywall at the pointof attachment-resulting in an unstable connection. Accordingly, thesesteps require additional manipulations of the junction box that candamage the surrounding drywall or the electrical junction box or thefinal fixtures.

Still further during the process of final electrical installation,electrician may accidentally damage the finished drywall around the box,particularly when manually removing debris and excess joint compoundfrom a large number of junction boxes, resulting in the requirement ofadditional touch up work to the drywall surface that has to be doneeither by the electrician or by a subsequent drywall finishingoperation.

Therefore, the process of completing dry wall and electrical finishinginvolves a series of steps by different tradespeople with differentexpertise and that can add expenses and delay to a building project.

SUMMARY OF THE INVENTION

The present invention is an electrical junction box cover and anassembly comprised of the electrical junction box together with thetemporary cover-to protect the box and the electrical fixtures andcables contained within the electrical during drywall finish work. Theinvention includes the electrical junction box, the temporary cover,attachment mechanisms for joining the cover to the junction box,electrical and data-outlets contained within the junction box, togetherwith cabling having a terminal end attached to the outlets and anintermediate end preferably contained within the junction box. Theassembly includes the completely wired and connected electrical junctionbox, with the temporary protective cover having been removed, such thatthe internal fixtures, outlets and structures, such as plugs, switches,and data ports, are substantially free of debris and other contaminantssuch as extra joint compound.

The invention includes an assembly which comprises the electricaljunction box and the temporary cover, together with the operativeelectrical and data components contained therein in any state ofcompletion. In some instances, the temporary cover may be placed overthe junction box with only bare wires, having a terminal end, containedtherein. In other instances, the wiring for electrical structures, ordata cabling can already be complete with the temporary cover in placeto protect these components, and an intermediate end of the wiring orcabling terminates on a plug/receptacle for attachment to buildingswiring or cabling. The assembly can include a drywall border surroundingthe electrical junction box wherein the temporary cover protects theinternal structures during a drywall finishing process.

The methods of the invention include the steps of removably installingthe junction box cover prior to installing drywall around the box,completing drywall finish work around the box with the removable coverin place, and removing the cover to permit access to the junction box.The methods of the invention include the steps of removing the junctionbox cover from its attachment to the junction box and attaching it tothe junction box prior to drywall installation and after the electricianhas wired the plug and or switch to the junction box. The outlets,switches, ports, and other functional components designed to be placedwithin the junction box can be installed by the electricianeither-before or after the drywall installation step. In either case,the internal structure of the electrical junction box remains free ofdebris and excess joint compound.

In one embodiment of the invention, the electrical junction box isfitted with switches, outlets, data ports, or other functional apparatusprior to being attached to the wall during electrical “rough in” duringthe construction. In this embodiment, large-scale production of anelectrical junction box is enabled wherein the electrical junction boxis preassembled with functional components already hard wired in place.This reduces the installation at the residential or commercial structureto essentially a single step whereby the entire assembly is simplyattached to the wall beam and the-intermediate end of the wiring issimply connected to the existing buildings wiring or cabling that isalready in place. In such an embodiment, the terminal end of the wiringis attached to the functional components, and typically terminatesoutside the electrical junction box at a free end separate from theterminal end. In either case the entire electrical junction box andelectrical switch/outlet/port component assembly are connected to thebuilding electrical/data connection by attaching the wires at the freeintermediate end of the assembly to the existing wiring in the building.

DESCRIPTION OF THE FIGURES

FIGS. 1a-1h are an electrical junction box and a temporary protectivecover showing the structure and design of the cover and electrical box,together with means for temporarily attaching the cover to the box.

FIGS. 2a-2f depict a second embodiment of a double electrical junctionbox and a temporary protective cover similar to the embodiment of FIGS.1a -1 h.

FIG. 3 is a flowchart illustrating one potential method of constructingthe assembly described herein, including drywall finishing steps andelectrical finishing steps.

FIGS. 4a-4c illustrate prototypes of the invention that are applicable,but not limited to, residential applications.

FIGS. 4d-4g illustrate prototypes of the invention that are applicable,but not limited to, commercial applications.

FIGS. 5a-5e illustrate prototypes of the invention that are applicable,but not limited to, residential applications.

FIGS. 5f-5h illustrate prototypes of the invention that are applicable,but not limited to, commercial applications.

FIGS. 6a-6b illustrate a round electrical junction box and a roundtemporary protective cover.

FIGS. 7a-7b illustrate a temporary protective cover secured to anelectrical junction box with drywall installed around the electricaljunction box pursuant to the invention.

FIGS. 8a-8c are a combination cover and box with the cover attached as abreak away component and designed to house a single outlet.

FIGS. 9a-9c are a combination cover and box with the cover attached as abreak away component and designed to house dual outlets.

FIG. 10 illustrates the connection of the combination cover and boxhaving a break-away attachment [structure] and sealable closures and/orports for containing completed wire or cable connections within theinterior of the assembled box and cover.

DETAILED DESCRIPTION OF THE INVENTION

This invention is electrical junction box covers and assembliescomprised of a removable cover for temporarily covering an electricaljunction box during finish work. The electrical junction box covertemporarily protects the electrical junction box, particularly duringdrywall finishing steps. Most importantly, the cooperative relationshipbetween the design of the temporary cover and industry-standardelectrical junction boxes prevents debris from entering the junction boxduring construction, particularly where debris would impede the abilityof an electrician to complete necessary wiring and electricalconnections. The protective cover may be releasably attached to theelectrical junction box then removed as desired, at any point during theconstruction process where the protection of the interior of thejunction box is desired, and then removed as desired.

The temporary protective cover may be releasably affixed to anelectrical junction box that is substantially completely wired,including a fully wired “hot” outlet, switch, or communication fixture(e.g., a cable, phone or Ethernet connection point). For the ease ofreference the functional related fixtures (together with electrical,data ports, lighting, optical, digital and connectors for theoutlets/fixtures contents of the electrical junction box, includingitems such as communication fixtures will be referred to collectively,but not exclusively, as an “outlet.” Furthermore, while the followingdescription relies on a temporary junction box cover that is sized andconfigured to engagingly mate with industry standard electrical junctionboxes, the present invention includes essentially any electrical box,including junction boxes, panels, arrays of switches and indicatorlights, arrays of fuses or relays, and includes larger electrical boxessuch as a main electrical panel, where the interior is protectableduring a portion of the construction process on surrounding structures.

Methods of installing the electrical junction box, the removableelectrical junction box cover, and for completing drywall and finishelectrical work are also included in the invention, including methodsfor covering the junction box and manipulating the placement, and wiringthereof, to maximize efficiency of the building process. INSERT B

The invention also includes completed assemblies featuring fullyconnected terminal ends of electrical wires and/or data cables where inthe outlet fixture is completely wired and contained within the assemblycomprised of the combination of the electrical junction box and theremovable cover. In this embodiment, the terminal ends of the wires orcables are completely connected to completely secured outlet within thejunction box and the opposite or immediate end is disposed outside thejunction box and available for connection to existing wiring at theresidential or commercial installation. For delivery and installationthe entire wiring/cabling, from the immediate end to the terminal endattached to the outlets may be contained within the interior housing ofthe junction box. In this embodiment, the only connection that need bemade is between the wires or cables existing at the structure and theintermediate end of the wiring or cables located outside the junctionbox, and may be joined.

In the following description of the embodiments illustrated in thefigures features generally relating to a single outlet configuration aredesignated with reference numbers in the 100s, while features generallyrelating to a double outlet configuration are designated with referencenumbers in the 200s, although one of ordinary skill in the art willappreciate that many of these structures are similar or identical inconfiguration and design and differ simply in dimensions between single,double, triplet and quad outlet configurations.

Referring to FIGS. 1a -1 h, the invention is comprised of an electricaljunction box cover 100 that is releasably attached to the electricaljunction box 170, the cover 100 includes a cover surface 110 and fourperimeter walls 120 each extending away from the cover surface 110, andterminating in an edge. Two of the peripheral walls 120 terminate in apair of first edges 121, while the other two terminate in a pair ofsecond edges 122. As described below, the first and second edge pairs121, 122 sealingly engage corresponding structures on the box 170 aboutthe outer periphery of each of the cover 100 and the electrical junctionbox 170. Accordingly, the overall dimensions of the cover 100,specifically the length of the peripheral wall 20, and hence the lengthof the first edges 121 and the second edges 122 are matched to thedimensions of the junction box 170. Accordingly, these dimensions forthe cover 100 match the industry standard dimensions for a box 170, butmay readily be altered according to the design of the junction box 170.

In a corresponding manner to the cover 100, the junction box 170 iscomprised of four box peripheral walls 191 that terminate at four upperedges. Two of the box peripheral walls 190, terminate at a pair of thirdedges 191, while the other two box peripheral walls 190 terminate at apair of fourth edges 192. A conforming engagement between the cover 100and the box 170 is created by providing a cover with dimensions suchthat the length of the first pair of edges 121 matches the length of thethird pair of edges 191 and the length of the second pair of edges 122matches the length of the fourth pair of edges 192.

The height of the peripheral wall 120 is greater than the height of thehighest point along a vertical distance of the outlet 160 extending awayfrom the plane formed by the outer periphery of the box 170, andpreferably less than one inch. This is simply to provide clearance whenthe first and second edge pairs 121, 122 are brought into engagementwith the third and fourth pairs of edges 191, 192 along substantiallythe outer periphery of the box 100 when the cover 100 is securely, butreleasably attached to the junction box 170 by virtue of the means forattachment 130. The perimeter of the cover 100, and preferably thesecond edge pair 122 may include one or more recesses 124 within theouter edge to provide a more effective seal between the outer peripheralwall of the junction box 170 and the edges 121, 122 of the perimeterwall 120 of the cover 100. The recesses 124 may be sized to provideclearance space to structures such as outlet tabs 162 of an outlet 160when the cover 100 is installed over an outlet 160. The one or morerecesses 124 may be sized to accommodate support structures for theoutlet 160 or specifically to have a greater length than the totallength of the distance between the outlet tabs 162. The outlet supportstructures such as may be traversed 172 to receive a fastener 132 thatalso traverses the removable cover to enter the complementary attachmentfixture 172 to allow for removable attachment of the cover 100 to thejunction box 170.

Accordingly, the cover 100 may also include one or more structures toprovide the function of releasably attaching the cover 100 to thejunction box 170. In the embodiment of FIG. 1 a, the attachmentstructure is comprised of holes 130 that traverse the body of the cover100 and have a meeting engagement with structure on the box 170 tofacilitate removable attachment of the cover 100. Also as seen in FIG. 1a, simple fasteners 132 may traverse both of the cover 100 and a fixtureassociated with the box 170 in order to provide for releaseableattachment of the cover 100 junction box 170 shown in FIG. 1 a.

Referring again to FIGS. 1a -1 f, the attachment means 130 provides aconnection point for releasably attaching the cover 100 to theelectrical junction box 170 at any point when the electrician hasfinished preparing the junction box 170 and expects that additionaltradespeople will be working around the box 170 such that theelectrician desires to protect the contents of the box 170 fromcontamination with debris. The attachment means 130 may be anymechanical expedient that provides for releasable attachment of thecover 100 to the box 170. As shown in, for example, FIGS. 1 a, 2 a, 4a-4 d, 4 g, 5 a-5 e and 7 a-b, a fastener 132 can traverse holes 130 inthe cover 100 and engage complimentary attachment features 172 formed inthe box 170. In the embodiment of FIG. 1 a, the complimentary attachmentfeature 172 is simply a receiving hole into which the fastener 132passes after traversing the body of the cover 100.

Other examples include a conventional screw, nail, pen, or tie,including zip ties or other adjustable ties that ensure close engagementbetween the cover 100 and the box 170.

Any attachment means 130 may be located in a recessed surface, atcorners of the cover, as is illustrated in, for example, FIG. 4d ). Theattachment structures 130 may also be recessed with respect to theopposite edge surface (inside bottom surface) of the cover 100 toaccommodate various junction box plaster ring 180 geometries. Thejunction box plaster rings 180 are commonly referred to as “mud rings”and are secured within the junction box 170.

In an embodiment of the invention featuring a junction box plaster ring180, the attachment means may connect the cover 100 to the plaster ring180 rather than directly to the box 170. Because the plastic ring 180 isnecessarily permanently attached to the box 170, this configurationprovides equivalent releasable connection of the cover to the box170/plaster ring 180 combination.

As described below in connection with the specific commercial junctionbox170, the recessed attachment features 130 are particularly preferredin commercial applications (e.g., FIG. 4d-4g ). In commercialapplications, each metal junction box 170 routinely surrounds a plasterring 180 to which sockets 160 are attached and the sockets 160 typicallyfeature an outlet tab 162 or plurality thereof that are disposed betweenthe sealing edges 121, 122, 191, 192 of both the cover 100 and the box170 respectively.

In an illustrative embodiment of the box 170, the box 170 hascomplimentary attachment features 172 (e.g., holes or bosses) for theattachment means 130 to engage and attach to, such as via fasteners 132.The goal of the shape and design of the peripheral wall 120 of the cover100 is to provide an effective dust and debris seal around the peripheryof the engagement between the lower edge of the peripheral wall 120 andthe upper edge of the wall of the box 170.

As noted above, the combination of the sealing engagement between thefirst and second edge pairs 121, 122 of the peripheral wall 120, theupper cover surface 110, and the sealing combination with the third andfourth edge pairs 191, 192 of the junction box 170 into the completedassembly to temporarily form a barrier between any components in theinterior of the junction box 170 and any source of debris orcontamination. While the contents of the junction box 170 may include afully wired box 170, completely connected to electrical wiring and/orcables at the terminal end thereof, including a “hot” outlet 160 whilethe finish work such as drywall, mudding, taping and painting iscompleted, the cover 100 also prevents the box 170 from being completelycovered during the installation of drywall. The cover 100 prevents thejunction box itself, as well as any associated outlets, from beingdamaged during drywall installation. Accordingly, whether or not thewiring or cable connections are complete, the cover 100 prevents debrissuch as drywall, spackle or paint from entering the box 170. This isparticularly important when the electrical junction box 170 containsfixtures such as ethernet cables, optical fibers, cable connections, andother sensitive electronic connectors that would be damaged, perhaps inways that are not immediately apparent to the naked eye, duringconstruction.

The cover 100 is sufficiently rigid and sized such that the dimensionsof the edge of the perimeter wall 120 match the specific junction box170 to which the cover 100 is releasably attached. As shown in FIGS.4-10, the junction boxes 170 may be sized to accommodate a plurality ofoutlets 160, but in each case, the outer periphery of the cover 100 issized to engagingly mate with the outer periphery of the top edges 121,122, 191, 192 of the junction box 170. Because of the meeting engagementof the box 170 and the cover 100, drywall installers can easily andcleanly cut around the both the cover 100 and the box 170 whenperforming a drywall finishing work. Therefore, when the cover is inplace, the entire junction box assembly exists as an intact unit whereinthe cover 100 protects the outlets disposed within the box 170 whilesubsequent drywall finishing processes are performed.

In this configuration, the electrician can complete all of the hotwiring functions, understanding that a drywall finishing process is yetto be completed, with an expectation that the electrical junction box,and the functional outlets contained therein, will be protected duringthe drywall process. This eliminates the need for the electrician who istrimming (installing plugs and switches) during the normal trimmingstage to spend any extra time trying to figure out what the “rough in”electrician did when wiring the project initially and eliminates theneed for the electrician to inspect the junction box 170 after thefinished drywall process. Thus, the completed assembly is minimallycomprised of the cover 100, the box 170, and the attachment means 130and functions as an intact unit to reduce the labor required for thefinal electrical trim process to a minimum, thereby saving time andmoney and improving the safety of all of the electrical and dataconnections formed within the junction box 170.

Referring to FIGS. 2a -2 f, the electrical junction box cover 200 isreleasably attached to the electrical junction box 270 generally asdescribed above. The cover 200 includes four peripheral walls 220extending away from the cover surface to 220 to form an enclosure. Twoof the peripheral walls 220 terminate in a first edge pair 221, whilethe second two terminate in a second edge pair 222. The first and secondpairs of edges 221, 222 sealingly engage corresponding structures on thebox 270 about the periphery of each of the cover 200 and the junctionbox 270. As with the single outlet embodiment, the overall dimensions ofthe cover 200 match the industry standard for a double outlet box 270,but may readily be altered according to the design of the junction box270. The height of each of the four peripheral walls is greater than thehighest point along a vertical distance from the faceplate of the outlet262 to the tallest feature of the outlet 260. Accordingly, eachperipheral wall 290 would have a larger vertical distance for an outlet260 comprising a toggle switch, compared to an electrical outletreceptacle.

Accordingly, the length and width of the pairs of edges 221, 222 arematched to the dimensions of the corresponding edges 291, 292 of thejunction box 270, which is typically, but not necessarily anindustry-standard dimension. With appropriate dimensions, sealingengagement is provided when the edges 221, 222 of the cover 200 arebrought into conforming engagement with the edges 291, 292 of the box270. As in the embodiment of figures la-lf, recesses 224 may be providedand sized to provide clearance space for structures such as the outlettabs 262 of the outlet 260 when the cover 200 is engaged with the outlet270. The recesses 224 are preferably formed in the second edge 222 ofthe cover 200, but may be formed in any edge structure to accommodatethe geometry of the outlet 260 and particularly the outlet tabs 262.

FIG. 3 is a flowchart illustrating an embodiment of a method 300 ofinstalling an electrical outlet 160 as described above with respect toFIGS. 1-to 2 and 4-10. The method outline of FIG. 3 assumes that theoutlets 160 are wired into the junction box 170 prior to installation ofthe removable cover 100. As noted above, however, the removable covercan be installed at any point at which a desire exists to protect theinternal space of the junction box 170 from contamination with debris.Accordingly, the flow chart of FIG. 3 is exemplary of one embodiment ofthe invention, and does not restrict performance of the invention toprecisely following the steps as indicated, or in the exact orderthereof, except as otherwise indicated herein.

Referring specifically to FIG. 3, in step 310 a the walls of a structureare erected by framers in a conventional manner requiring only that theframe is adequate to support the electrical junction box 170 asdescribed herein. For example, the walls may be erected using wood ormetal studs for walls and wood or metal beams for the ceilings andfloors in a conventional manner, as long as these structures provideadequate structural support for attachment of drywall as describedherein and placement of the junction box 170.

In step 310 b, the electrician runs electrical wiring from a main panelto the desired location of the electrical junction box 170. This isconsidered a minimal step to establish electrical connection from themain panel to each of a plurality of junction boxes 170. However as isapparent from the disclosure herein, in addition to electrical wiringthe step can include establishing a functional connection for datacables, optical fibers, ethernet connections, LAN connections, and anymanner of electrical, optical, digital, or other connection thatrequires establishing a tangible, physical connection to a point ofaccess by an inhabitant of a space who operates a switch, or utilizes anoutlet, or performs any other conventional function associated with ajunction box 170.

As noted above, the invention also includes an embodiment wherebyelectrical or data connection is established from a central or mainaccess panel and terminates near, but outside, the enclosure of thejunction box 170 such that a pre-assembled junction box/cover assembly101 can be provided requiring only formation of an electronic or dataconnection at an intermediate point (outside the junction box 170). Instep 320 an electrician attaches the box 170 to the wall studs orceiling joists and routes the wiring from the main panel to the box 170.

In step 330, the electrician snaps off a portion of the metal outlettabs prior to installing the outlet 160 in the box 170. The removal of aportion of the outlet tabs 162 gives the drywall installers a cleanerbox to work around without any significant protrusions from the outlet160 sticking out beyond the perimeter of the box 170. The outlet tabs162, 262 are shown in FIGS. 1a and 2a , and are shown removed in FIGS.5c -5 e. In some embodiments, the outlet tabs 162, 262 are completelybroken off for standard outlets and switches. In other embodiments, suchas for decora outlets and switches, only the outside portion of outlettabs 162 are broken off leaving the middle portion of the outlet tab forinstallation of a faceplate cover later (FIGS. 5c-5e ).

In step 340 the electrician installs the outlet in the box. At thispoint the electrical connection to the main panel is complete and theoutlet is hot once the main panel is activated.

In step 350, the electrician installs the temporary protective coverusing complementary attachment features on opposite corners of the coverthat line up with attachment features on the box.

In step 360, the drywall is installed over the wall studs and theceiling joists. The installers cut out panels around the boxes that wereinstalled by the electrician. The cover over the box protrudes from thestuds sufficiently to ensure that the box is not inadvertently coveredduring the drywall process.

In step 370, the finish work is completed around the box. The finishwork may include taping, mudding, sanding and painting the drywall.

Beneficially, step 380 does not have to be done by an electrician. Step380 could be completed by a builder's handyman or someone with onlygeneral knowledge of outlets at a much lower cost than hiring anelectrician. In step 380, the cover is removed by detaching thetemporary protective cover from the box (e.g., by removing the fastenersin the opposite corners of the cover that attach the cover to the box).

In step 385 a, the outlet is loosened (but not removed) from the box.

In step 385 b, the breakaway reinforcement tabs are removed from theinside of the cover (e.g., broken off) and then placed between theoutlet and the box at the top and bottom of the outlet. When needed, theoutlet(s) are then tightened back to the box with the tabs creating astable installation of the outlet against the box (FIGS. 5d and 5e ).

In step 390, the final finished cover or fixture is installed over theoutlet to complete the process.

In some embodiments, the cover 100 includes reinforcement tabs 150.Reinforcement tabs 150 may be breakaway reinforcement tabs 150 that canbe detached from the cover 100 and used to stabilize the outlet 160attachment to the box 170. Detachment of the reinforcement tabs from thecover 100 may occur by bending and fracturing the connection of thereinforcement tab 150 to the cover 100. The connection of thereinforcement tabs 150 to the cover 100 may be similar in geometry to aliving hinge, as is known in the art of plastic injection molding.

The breakaway reinforcement tabs 150 are molded into the box 170 or thecover 110 and typically project up from a bottom surface or side surfaceof the box 170 or cover 110. Once broken off, the reinforcement tabs 150are inserted between the outlet 160 and the box 170. Placement of thereinforcement tabs 150 between the outlet 160 and the box 170 provides asolid reaction surface for the installed outlet 160 to be securedagainst. In some embodiments, the reinforcement tabs 150 each includeone or more slots 152 to accommodate fastening the outlet 160 to the box170 and include a receiving abutment (not shown) to slots 152.

Referring to FIGS. 4a -4 e, a residential embodiment of the combinationcover 100 and box 170 is shown revealing internal structures of each.The embodiment features reinforcement tabs 150 projecting up from aninterior surface of the cover 110 along the long axial length thereof.The second pair of edges 122 each have recesses 124 to accommodateplacement of an outlet 160, including outlet tabs 162 therein. Theembodiment of FIG. 4a also features a holding fixture 131 for easyattachment of a fastener 132. The holding fixture 131 is molded into anexternal surface of the Box 170 for easy access when releasably engagingthe cover 100 to the box 170. In this embodiment, the attachmentfunction is performed by simply removing the fasteners 132 from theholding fixture 131 and passing the faster 132 through the openings inthe attachment means 130 to reversibly secure the cover 100 to the box170. When attached, the conforming edge pairs 121, 122 and 191, 192 willeffectively seal the interior contents of the box against contaminationand debris. The interior of the box 170 shows ports 151 molded into therear surface of the box 170. The ports 151 are comprised of an openingtemporarily closed with a snap tab 152 that is removable to allowelectrical wiring or data cabling to be inserted into the box 174 foroperative or functional attachment to outlet 160.

FIGS. 4f-4g are atypical commercial embodiment showing a junction boxplastering 180 (or “mud ring”) attached to an outlet 160. The exteriorof the plastering ring 180 contains mating fixtures 153 that matchcorresponding attachment points 154 on the box 170. As illustrated inFIG. 4g , by aligning the mating fixtures 153 with the attachment points154 the combination of the box 170 and plastering ring 180 securelylocates the outlet 160 in the combined assembly. To protect the outlet160, cover 100 is oriented above the outlet 160 and fastener 132 ispassed through the attachment fixture 130 to secure the combinedassembly.

Referring to FIG. 5a -g, a double outlet embodiment is comprised of aholding fixture 231 affixed to the external portion of a peripheral wall290 of the box 270. The reinforcement tabs 250 are disposed in atransverse orientation on the interior surface of the cover 200. Theattachment fixture 272 is disposed at opposite corners of the box 272engage with the attachment means 230 of the cover 200. FIGS. 5b and 5creveal a box 270 having ports located in a bottom surface of the box 270and having snap tabs 252 removed from a pair of the ports 151 forinsertion of electrical wiring or data communication cabling. In FIG. 5c, a pair of outlets to 60 are shown in a conventional orientation withinthe box 270.

FIG. 5f shows an embodiment including additional attachment features 272positioned such that a fastener 232 (not shown here) would traverse thecover 200 and engage empty mating fixtures 253 on the plastering ring280.

FIGS. 6a and 6b illustrate embodiments for covering round electricaljunction box 670. The round electrical junction box 670 may betemporarily covered and protected by a corresponding round electricaljunction box cover 600 a (FIG. 6a ), 600 b (FIG. 6b ). Electriciansinstall one of the round electrical junction box covers 600 a, 600 bhaving outlet inserts 602 a, 602 b and hooks 604 a (FIG. 6a ) or cutouts604 b (FIG. 6b ) over the outlet 660. The hooks 604 a or cutouts 604 bprovide geometry to hold the wire of the outlet 160 that is plugged intoit in place, when the wire is snaked through at least one of the hooks604 a or cutouts 604 a. In some embodiments this allows othertradespeople to have temporary power throughout the house during thecourse of construction as compared to using the one outlet typicallysupplied during rough in or using a temporary electrical pole withpower.

FIGS. 7a-7b are photos of an illustrative prototype of a temporaryprotective cover secured to an electrical junction box with drywallinstalled around the box according to embodiments of the invention.

Referring to FIGS. 8a -8 c, the invention includes a combined assembly101 having a box 170 attached to a cover 100 by a breakaway fixture 155that allows the manufacture of the combined assembly 101 by molding aunitary structure wherein the box 170 and the cover 100 can be readilyseparated and utilized as described above.

The breakaway fixture 155 is any structural feature that allows readyseparation of the cover 110 from the box 170 by manually separating thetwo components by hand. Typically, one simply grasps each component,rotates the components around an axis formed by the break away component155 and physically separates the two pieces. A number of simpleexpedients are known for such a function, including a living hinge asdescribed above, a perforated then, plastic molded segment, or any of anumber of breakaway tabs provide this function.

As in the above-described embodiments, the edges of both the cover 100and the box 170 are sized and oriented to fit into conforming engagementabout the periphery of each edge. In use, the user simply breaksstructure 155 to separate the cover 100 from the box 170 and assemblesthe wiring and electrical components as described above. FIG. 8c , is across-section view around line 8C of FIG. 8B. FIGS. 9a-9c are a dualoutlet embodiment of the combination component of FIGS. 8a -8 c.

The advantage of the combination component is that the appropriately-sized corresponding cover 200 is molded at the same time as the box 207and so the conforming engagement between the box 270 and the cover 200is assured. Careful control of the molded dimensions ensures that thebreakaway fixture 155 attachment means between the cover 200 and the box270 are in excellent alignment and ensures a secure assembly of thefinal combination.

For the embodiment of FIGS. 8a-8c and 9a -9 c, the user typicallyfollows the steps of introducing electrical wiring or communicationcabling through the port 151, 251 and then attaches the wiring/cablingto the outlet 160, 260. Attachment fixtures on each of the box 170, 270are pre-molded to fit standard corresponding attachment fixtures on theoutlet 160, 270. Once electrical or data communication connection ismade between the wiring and the outlet 160, 270, the outlet is affixedto the box 170, 270 and secured in place. The cover 100, 200 is securedin place by virtue of the attachment means 130, at any point at whichthe outlet 160, 270 is secure. As described below in connection withFIG. 10, the wiring or data communication cabling may have a relativelyshort lead terminating at an intermediate end and of a length that issuitable to be contained within the box 170, 270. Preferably, this shortwiring/cabling lead terminates in a simple connector, but may be left asa bare wire or cable. For mass assembly, the short wire/cable lead canbe folded or coiled up, reinserted through port 151, 251 such that theentire wiring assembly is contained within the box 170, 270. At anypoint following placement of the cover 100, 200 in conforming engagementwith the box 170, 270, the attachment means is used to secure the cover100, 200 to the box 170, 270. Upon secure engagement, such as withfastener 132, 232, the entire assembly can be shipped and is ready forinstallation at a building site.

Referring to FIG. 10, as noted above, the breakaway fixture 155 is anysimple molded structural expedient that allows ready separation of thebox component 170, 270 from the cover component 100, 200. An option forthe port 151, 251 is either an open structure that is created, such aswith the snap away tabs 152, 252 or may be created to be resealable suchas closure 154 that can be opened for insertion of the wiring/cablinginto the housing of the box 170. In such an embodiment, the method ofassembly simply includes opening the closure 154, connection of thewiring/cabling to outlet 160, 170, followed by placing the entireelectrical/cabling lead (and optionally half of a connector pair) withinthe housing of the box 170, 270 and closing the closure 154. The cover100 and box 170 are assembled in the same fashion as described above.However, when the combined component is used at the building site, theuser simply opens closure 154, retrieves the intermediate and of thewiring/cabling and attaches the wiring/cabling to the pre-existingwiring/cabling that is already in place at the wall, ceiling, or otherrough structure at the building site. At this point the entireelectrical assembly, with the cover 100 in place, is ready forinstallation of the drywall around the entire component assembly,requiring only removal of the cover 100 and the installation of acosmetic or decorative cover plate to complete the entirety of thewiring/cabling and the outlet 160, 270 installation process.

Various examples have been described and photos of prototypes includingfeatures of the embodiments have been provided. These specific examplesand other examples are within the spirit of the invention are within thescope of the following claims.

I claim:
 1. An assembly comprising: an electrical junction boxcomprising a housing and at least one outlet disposed therein; whereinthe at least one outlet has a wired connection operably connectedthereto at a terminal of a wire; a temporary cover releasably attachedto the electrical junction box about a periphery of the opening; meansfor releasably attaching the temporary cover to the electrical junctionbox
 2. The assembly of claim 1, wherein the electrical junction box isfurther comprised of a junction box plaster ring.
 3. The assembly ofclaim 2, wherein the outlet is affixed to the junction box plaster ring.4. The assembly of claim 2, wherein the junction box plaster ring isaffixed to the electrical junction box.
 5. The assembly of claim 1,wherein the electrical junction box housing comprises four peripheralbox walls each terminating in an upper edge.
 6. The assembly of claim 5,wherein a first pair of the four peripheral walls terminate in a pair offirst edges of substantially equivalent length.
 7. The assembly of claim5, wherein a second pair of the four peripheral walls terminate in apair of second edges of substantially equivalent length.
 8. The assemblyof claim 5, wherein the cover is comprised of four peripheral coverwalls each terminating in a lower edge.
 9. The assembly of claim 8,wherein a first pair of the four peripheral cover walls terminate in apair of first edges of substantially equivalent length.
 10. The assemblyof claim 9, wherein a second pair of the four peripheral cover wallsterminate in a pair of second edges of substantially equivalent length.11. The assembly of claim 9, wherein the pair of first edges of the boxperipheral walls is in conforming engagement to the pair of first edgesof the cover peripheral walls and held in place by the means forreleasably attaching the temporary cover to the junction box.
 12. Theassembly of claim 10, wherein each of the pair of second edges of theperipheral cover walls is further comprised of a recess.
 13. Theassembly of claim 8, where in each edge of the four peripheral box wallsand each edge of the four peripheral cover walls is in conformingengagement.
 14. The assembly of claim 1, wherein the housing of theelectrical junction box is comprised of a closure traversed by the wireand terminating at an intermediate and thereof.
 15. An assemblycomprising: an electrical junction box comprising a housing having anopening surrounded by four peripheral box walls each terminating in anupper edge; a temporary cover comprised of four peripheral cover wallseach terminating in a lower edge and wherein the cover is sized to bereleasably attached to the electrical junction box; wherein theelectrical junction box and the temporary cover are co-molded and joinedby a breakaway fixture for manual detachment of the electrical junctionbox and the temporary cover.
 16. The assembly of claim 16 furthercomprising an outlet affixed to the electrical junction box andconnected to a length of wire having a terminal and attached to theoutlet and an intermediate and disposed within the housing of theelectrical junction box.
 17. The assembly of claim 17 wherein theelectrical junction box housing is further comprised of an opening witha mating closure for access to the interior of the electrical junctionbox housing.
 18. The assembly of claim 15 wherein the edges of the fourperipheral box walls and edges of the four peripheral cover walls areheld in conforming engagement by means for releasably attaching thetemporary cover to the electrical junction box.